Process for producing sulphur



PROCESS FOR PRODUCING SULPHUR Filed Dec. 17 1942 Patented Sert is, 1945 l PRCSS FOB PRODUCING SULPHUR Minor C. K. Jones, Mountainslde, N. J., assignor to Standard Oll Development Company, a eorporatlon of Delaware Application December 11. 1942. serial No. 469.280

Claims.

The present invention relates to the utilization and disposal of high hydrogen sulphide content gases to produce elemental sulphur by reaction with SO2 in the presence of a silica gel activated of the sulphur. Consequently, for the objections noted. this particular process has not been generally adopted by those industries facing the problem of hydrogen sulphide disposal. Ef-

with oxides of boron, sodium and potassium, at 5 forts have been made in the past to carry out atmospheric or superatmospheric pressure and at the reaction between Has and SO: in an anelevated temperatures. hydrous state, but these attempts have not In many industrial processes waste gases conevolved a practical process. taining hydrogen sulphide are produced in the I have now found a practical method whereby plant operation. For example, in'the manufac- 10 the reaction between Has and SO2 to form eleture of illuminating and fuel gas by the destruemental sulphur and water can be carried out. tive distillation of coal, hydrogen sulphide is In general, this method involves passing a mixpresent in the raw gas and generally the gases ture of hydrogen sulphide and sulphur dioxide, are treated to remove the hydrogen sulphide. preferably in approximately molecular propor- Hydrogen sulphide is also a constituent in natul5 tions, over a suitable catalyst under such temral gas and is produced also in petroleum reperature conditions as to give a practical rate of iineries when operating on sour crudes such as reaction, and fractionally condensing the reacthose produced in the West Texas eld. There tion products so that sulphur is removed in the are, of course, many other sources of hydrogen :molten state. While pressures above atmossulphide which must be disposed ofin connection pheric are not essential in my process, the size with various manufacturing operations. of the equipment can be reduced by employing As is well known. hydrogen sulphide is a toxic, pressures up to several hundred pounds per malodorous gas and may become a health hazard square inch gauge may be used. A suitable catif allowed to escape into the atmosphere in alyst for this purpose comprises a major proporquantities. In the vicinity of gas wells which tion of silica, such as silica gel or other form of are producing sour gas, extreme precautions finely divided silica, to which is added a minor must therefore be taken to prevent the escape proportion of certain activators. The oxides of of this gas into the atmosphere. Now, of course, boron. sodium, and potassium are particularly from the standpoint of conservation, large quan eifective, although other alkali and alkali earth tities of hydrogen sulphide are available, conoxides may be used. In certain instances it is taining potentially an enormous amount of sulalso desirable to have present a certain percentphur. It has been reported that in the McKamie age of aluminum oxide. Furthermore, the catiield in Arkansas, hydrogen sulphide equivalent alyst may be prepared by activating the surface to 96 tons of sulphur per day are produced. In of finely divided silica, such as silica gel, with aca large oil refinery operating on sour crudes. the tivating agents. In other cases, it is desirable quantity may be of the order of 35 to 40 tons of actually to melt the components together to form sulphur per day. The usual method of disposa glass-like material which is then cooled and ing of this gas is to burn it under boilers. stills, powdered to the desired degree. and the like, thus converting the hydrogen sul- One object of my present invention therefore phide to SO2 and water, which SO: is less objec- 40 is to provide an eiiicient, economical and satistionable in the atmosphere than the hydrogen factory method for disposing of HzS. sulphide. The releaseof large quantities of S0: A more specific object of my invention is to into the atmosphere is wasteful oi' the contained provide a continuous process where large quansulphur and, at the same time, its presence is tities of gases containing Has may be treated catdetrimental to vegetation and causes other damalytically to convert them to gases or vapors age in the vicinity. v which may be safely discharged into the atmos- Methods of hydrogen sulphide disposal and phere or further processed or utilized, and, at the sulphur recovery have been proposed, such as the same time, to recover from the process elemental reaction of HzS and SO: to form free sulphur. sulphur. v but this reaction in general is carried out in an Other objects of my invention will appear from aqueous medium, thus involving the handling of the following more detailed description and disproportionate quantities of liquids and the claims. separation of the sulphur from large quantities In order to afford a better understanding of or water. The expense involved vin such oper'amy invention I have shown in the accompanying tions is very large and not justified by the price drawing diagrammatically. a flow plan which illustrates a preferred modication of my invention.

I shall now set forth a specific example illustrating my invention and for clarity of exposition, I shall refer to the accompanying drawing.

We will assume that a refinery processing a sour crude has a large volume of normally gaseous constituents containing substantial quantities of H2S and that it is necessary for purposes of public health, etc., to convert the hydrogen sulphide into a non-toxic gas or other material which may be discharged into the atmosphere or into streams and, at the same time, to recover sulphur as a by-product. Ordinarily, the H2B would be associated with the ethane. propane, or other Ca and Ca hydrocarbons.

Referring in detail to the drawing', the cut or fraction in question is introduced into the present system from some reilnery source through line I, thence heated in a heater 4, and thence conducted via line 5 into fractionating column III. In fractionating column I0 the C: hydrocarbons are taken ofi overhead through line I2, while the propane is taken off as bottoms through line l5. The HzS fraction, on the other hand, is recovered through line I8 and then specially processed in the manner which will be presently described. Speaking generally at first, it is pointed out that the I-IzS will eventually be treated with a iiuidized catalyst in a reaction chamber wherein it will be converted to water vapor or steam and sulphur in the presence of an oxidizing gas, such as ordinary air. To this end, therefore, the ms in line I8 is split between two streams 20 and 22 in the ratio of about 1 volume of H28 in line to 2 volumes in line 22. The HaS in line 20 is discharged into air inlet stream 25 where it is mixed with suiiicient air to burn the HzS and then the mixture is burned in furnace 30, the SO2 together, of course, with water vapor, steam and nitrogen being withdrawn through line and mixed with -the balance of the original HzS in line 40, whereupon it is discharged into a heater 42 and thence discharged into the bottom of reaction chamber 45 containing a powdered catalyst material adapted to accelerate or `advance the reaction between H2S and SO2. The catalyst preferably contains silica activated with a small amount of boron oxide.

With respect to the catalyst, I have found that good results are obtained by using the following composition:

Per cent by weight SiO (sand) 80 B203 12 NazO 4 A1203 4 These proportions may be varied considerably with respect to the B203 down to 1%, and with respect to the Na2O also, which may vary from 1 to 6% or so. Instead of using Naro, I may use K2O. As previously indicated, other acid radicals may be employed instead of B202. The A1203 may be omitted from the composition but its presence is beneficial. I consider the SiO2 and the acidic anhydride to comprise the important components in my catalyst.

The catalyst is ground to -a particle size of from 20-400 mesh, preferably somewhere in the range of from 100-200 mesh, and the entering reactants pass upwardly into the reactor 45 through the foraminous memlber 44 which may be an ordinary screen or grid plate positioned, as shown, at near the bottom of the reactor. The superficial velocity of the gases and/or vapors in reassenso actor 45 is controlled somewhere within the limita of from 2 to 3 to 20 feet per second, lpreferably from 5 to 10 feet per second. 'I'he rate of ow of vapors with the catalyst suspended is such. within the reactor 45, that the catalyst is maintained in the form of a iluidized," turbulent, highly agitated mass resembling a boiling liquid. This mass of material may have a density of 5-12 lb's. per cubic foot and is characterized by the fact that while the general flow of catalyst is upwardly, there are numerous cross currents and downwardly flowing streams, al1 of which create a condition of intimate and complete mixing, furthering the condition of substantially uniform temperature conditions throughout the reactor. Ordinarily the reactants remain resident in the reaction zone for a period of from 5 to 15 seconds, more or less, and the suspension then passes into a cyclone separator 50 superposed at the -top of the reactor as shown. In the cyclone or other separator 50, the catalyst is separated and gravitates back into the catalyst chamber 45.

In the particular operation in question, the catalyst does not require regeneration, since the operation is such that carbonaceous deposits are not formed on the catalyst. Hence the process may.continue without interruption for an extended period of time, in fact, until the catalyst becomes such that it is no longer active, which may be a period of several months.

The vapors are withdrawn overhead from the cyclone separator 50 through line 55 and thence pass into a sulphur condenser 50 where the sulphur is condensed to a liquefied state and withdrawn from the system through line 52. The steam, water vapor and other gas, on the other hand, are withdrawn overhead from condenser through line 10 and thence passed into a water condenser 12 from which the water may be withdrawn through line 15, while the permanent gases may be discharged from the system through line 18V. A portion of the gas in line l0 may be re- :ys'cled through line 80 into the reaction chamber While I have shown merely one cyclone separator 50 for separating catalyst from the reaction gases and vapors, it is to be understood that I prefer to employ a plurality of these separators supplemented by one or more electrical precipitators, in order to insure complete removal of catalyst from gases.

Another modification of my invention relates to expanding the internal diameter of chamber Q5 to form a disengaging chamber having a. depth of 11-12 feet wherein the superilcial velocity of the gases is reduced to 0.5 to 1 foot per second, whereupon the main bulk of the catalyst, namely, 98-99% or more of the catalyst settles and gravitates out of the gases and returns to the main bulk of the catalyst in the lower portion of the reaction chamber 45. In this modification of my reactor, I of course eliminate a large number of cyclone separators and other gas-solid cpntact separating devices and therefore eiiect considerable economy in equipment. Attention is also directed to the fact that I may feed fresh or make-up catalyst to the reactor from hopper Il l through line |02 and, at the same time, withdraw catalyst through valved bottom draw-off pipe |05 extending above the grid plate 44, thus replenishing the catalyst when necessary without interrupting the operation Since the reaction is exothermic, I prefer to withdraw catalyst from reactor 45 continuously, cool it to say 300 F. to l500 F. and return it via hOD'Der |00 and Pipe W2 undue temperature rises.

I have shown in the drawing, a modincation which permits numerous alterations to be made by those skilled in the art without departing from the spirit thereof. Thus the system which I have shown is adapted to be provided with various known expedients for conserving heat by countercurrent heat interchange between fluids and/or solids of diierent temperatures. These expedients will be readily apparent to engineers and for clarity I have not included all of the possi-ble ramiiications of my invention in this present description. I wish to mention that a portion of the recovered sulphur from 82 could be burned and SO2 introduced at line 3i without burning HzS from the feed gas. Such a modification would permit utilizing the process described on a mixture containing other gases than HzS, which should not be contaminated with nitrogen nor burned.

Further illustrating my invention, particularly with reference to operating conditions, I wish to point out that as to the main reaction taking place, that is SO2 and HaS to produce sulphur, experiments carried out at 896 F. were made to determine whether any advantage would be gained by using the gases in other than molecular proportions. 'Ihe following tables lshow the results of these experiments:

Per cent of Per cent Per cent theoretical His 80| yield obtained In this case the conditions were set so as to give only partial theoretical yield. The tests showed that .best results were attained by equal molecular proportions.

While the reaction takes place vslowly at lower temperatures, experimental results show 'that increasing the temperature hastens the speed of reaction. For instance, when a mixture of hydrogen sulphide and sulphur dioxide in approximately molecular proportions was passedover an activated silica catalyst with a very short time of contact, say 2-3 seconds, in order that only partial conversion would be attained, thereby allowing the eiects of temperature to be observed, the

following results were obtained:

Per cent Temperature theoretical conversion In the preferred modiilcation of my invention, I prefer to have the catalyst in such a form that the gases pass upwardly concurrently with the catalyst causing the catalyst to be iiuidized and to behave like a boiling liquid. Preferably the superficial velocity of the gas is so regulated as not to carry the catalyst in substantial quantities out of the catalyst chamber but with suillcient velocity to maintain the catalyst in a iluid condition. This aas rate will vary somewhat with the specific gravity of the catalyst involved. but in general the gas velocity will be o! the order ci 0.5 to 5 feet per second. As to temperature, since experimental results show that the reaction takes place over a wide range, a portion of which is too high to -be carried out in conventional equipment, I prefer to operate somewhere in the middle of the range. say from '100 F. to 1150 F.. preferably in the range of from 850 F. to 1000 F. Under these latter conditions. usual materials of construction are available and the rate of reaction will be satisfactory and the sulphur produced will be in the form oi vapor.

In order to remove the sulphur from the reaction products it is quite essential that the temperature be maintained at such a point that the water vapor present is not condensed to water. and further it is desired that the sulphurbe removed in its most fluid form; that is, at the temperature where the more viscous forms o! sulphur are not produced. I therefore prefer to maintain the temperature ot the sulphur condenser Ibetween 250 F. and 300 F. Under these conditions the sulphur is removed as a liquid product which is free owing, and the water vapors pass out in a somewhat superhcated condition.

Obviously, many modiilcations of my invention will appear to those who are familiar` with this art. For instance, instead of dividing the H18 stream in line I8 into one part'discharged into line 20 and two parts by volume into line 22, other proportions may be used, such as equal parts oi the HaS stream into each line.

In the speciiic example above set forth, I have described the method of recovering sulphur irom refinery gases. Obviously the same process could be applied to gases from any source which contained appreciable quantities of HzS, it being 4Q preferable oi course to separate the HzS from the other gases by fractional distillation or by some other convenient method, although the present invention could be applied directly to a mixed gas containing HzS as the means of Has removal.

What I claim is:

1. The method of producing sulphur from hydrogen sulphide which comprises maintaining a mass of powdered catalyst in a reaction zone in the form of a dense suspension, continuously forcing into said reaction zone a mixture of about equal molecular proportions of SO: and Has at elevated temperatures, regulating the superficial velocity of the gaseous mixture in said reaction zone to cause the catalyst to be maintained in the form of a turbulent, dense suspension, permitting the reactance to remain in the reaction zone for a period of time suilicient to cause the desired conversion of hydrogen sulphide to sulphur by interaction with S02, withdrawing the reaction products, cooling to a temperature sumcient to liquery the sulphur and withdrawing the latter from the system.

2. 'I'he method of claim 1, carried out at a temperature of about 896 F. l

3. A continuous process for producing sulphur from H2B which comprises forming a dense suspension of a powdered catalyst consisting of SiO: and a minor proportion of B20: in a reaction zone by simultaneously discharging said catalyst and gases containing about equal molecular proportions of B2S and S0: into said zone, causing the gases to ilow upward in said zone at a superficial velocity such that the catalyst due to slippage and delayed settling becomes compacted into a dense yet highly iluid mass resembling a liquid, controlling the temperature in the reaction zone within active reaction temperatures, withdrawing the reaction products trom the reaction zone and recovering sulphur therefrom. A

4. The method of recovering sulphur from hy drocarbon gases containing hydrogen sulphide which comprises fractionating the gases to separate a hydrogen sulphide fraction, oxidizing Aa portion of said hydrogen sulphide, combining the sulphur dioxide thus formed with the untreated portion of said hydrogen sulphide in about equal molecular amounts, discharging the mixture into a reaction chamber where it contacts a powdered catalyetmaterial, passing the gas mixture upwardly through the reaction chamber at such a rate of ow as to form a dense turbulent, ebullie'ntsuspension oi' the powdered catalyst resembling a boiling liquid, permitting the mixture of hydrogen sulphide and sulphur dioxide to remain in said suspension for a suilicient period of time to convert the hydrogen sulphide and sulphur dioxide into water and elemental sulphur, removing the reaction products from said suspension and said reaction chamber, cooling the products to cause liquefaction of the sulphur, and recovering the said sulphur.

5. The method set forth in claim 4 wherein the catalyst is silica containing a minor` proportion oi B203.

6. The method of producing sulphur from hydrogen sulphide which comprises maintainingl a mass of powdered catalyst in a reaction zone,

` continuously forcing into said reaction zone a mixture of sulphur dioxide and hydrogen sulphide in about equal molecular proportions at elevated temperatures, regulating the-velocity of the gas mixture in said reaction zone to cause the catalyst to be maintained in the form of a turbulent den'se suspension resembling a boiling liquid, permitting the reactants to remain in the reaction zone for a period of time suilicient to cause the desired conversion of hydrogen sulphide to sulphur Iby interaction with sulphur dioxide withdrawing the reaction products from said suspension and reaction zone, cooling to a temperature suilicient l to liquefy the sulphur and withdrawing the latter from the system.

'1. The method set forth in claim 6 wherein the catalyst is silica containing a minor proportionl of B203.

8. The method of producing sulphur from hy. drogen sulphide which comprises maintaining a catalyst mass of powdered silica containing a minor proportion of B203 in a reaction zone in the form of a dense suspension, continuously forcing into said reaction zone a mixture oi S03 and Has at elevated temperatures, regulating the superilcial velocity of the gaseous mixture in said reaction zone to causey the catalyst to be maintained in. the form of a turbulent, dense suspension, permitting the reactants to remain in the reaction zone for a period of time suiilcient to cause the desired conversion oi.' hydrogen sulphide to sulphur by interaction with SO2, withdrawing the reaction products, cooling to a temperature sumcient to liquefy the sulphur and withdrawing the latter from the system.

9. The method of recovering sulphur from hydrocarbon gases containing hydrogen sulphide which comprises fractionating the gases to separate a hydrogen sulphide fraction, oxidizing a portion of said hydrogen sulphide, combining the sulphur dioxide thus formed with the untreated portion oi. said hydrogen sulphide in about equal molecular amounts, discharging the mixture into a reaction chamber where it contacts a powdered silica catalyst containing a minor proportion of B203. passing the gas mixture upwardly through the reaction chamber at such a rate of ilow as to form a dense turbulent, ebullient suspension of the powdered catalyst resembling a boiling liquid, permitting the mixture of hydrogen sulphide and sulphur dioxide to remain in said suspension for a sumcient period of time to convert the hydrogen sulphide and sulphur dioxide into water and elemental sulphur, removing the reaction products from said suspension and said reaction chamber, cooling the products to cause liquefaction of the sulphur, and recovering the said sulphur.

10. The method of producing sulphur from hydrogen sulphide which comprises maintaining a catalyst mass of powdered silica containing a minor proportion of B203 in a reaction zone, continuously forcing into said reaction zone a mixture of sulphur dioxide and hydrogen sulphide in about equal molecular proportions at elevated temperatures, regulating the velocity of the gas mixture in said reaction zone to cause the catalyst to be maintained in the form of a turbulent dense suspension resembling a boiling liquid, permltting the reactants to remain in the reaction zone for a period of time suiiicient to cause the desired conversion of hydrogen sulphide to sulphur by interaction with sulphur dioxide, withdrawing the reaction products from said suspension and reaction zone, cooling to a temperature suihcient to liquefy the sulphur and withdrawing the latter from the system.

MINOR C. K. JONES. 

